Nonwoven antimicrobial scrub pad

ABSTRACT

An abrasive article comprising a nonwoven substrate material impregnated with a first and second formulation. The first and second formulations have broad spectrum antimicrobial effectiveness against one or more microbial organisms. The first and second formulations include the same or different polymer compositions, which include one or more antimicrobial agents and abrasive particles uniformly dispersed in the polymer compositions.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation of U.S. patent application Ser. No.14/824,874, filed Aug. 12, 2015, entitled “NONWOVEN ANTIMICROBIAL SCRUBPAD”, to Soumyajit BASU et al., which claims priority under 35 U.S.C. §119(a)-(d) to Indian application 3970/CHE/2014, filed Aug. 13, 2014,entitled “NONWOVEN ANTIMICROBIAL SCRUB PAD”, to Soumyajit BASU et al.,which applications are incorporated by reference herein in theirentireties.

FIELD OF THE INVENTION

The present invention relates generally to nonwoven abrasive articlesand, more particularly, to nonwoven abrasive articles having anantimicrobial agent.

BACKGROUND

Nonwoven abrasive articles used for cleaning, such as nonwoven abrasivescrub pads, can harbor microorganisms such as bacteria and fungi thatcan thrive and rapidly multiply in moist environments. Consequently, itis desirable to use materials that are effective at cleaning and thatcontrol or prevent the growth of unwanted microorganisms on nonwovenabrasive articles. Although various approaches have been taken to try tosolve the problem of microbial growth on nonwoven abrasive articles usedfor cleaning, such approaches have not produced nonwoven abrasivearticles that have long lasting effects on a broad spectrum oforganisms.

Therefore, there continues to be a demand for improved nonwoven abrasivearticles.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1 includes an illustration of a perspective view of a nonwovenabrasive article according to an embodiment.

FIG. 2 includes an illustration (a magnified photograph 1.6×) of asurface view of a callout portion of the embodiment of FIG. 1.

FIG. 3 includes an illustration (a magnified photograph 1.6×) of aninterior view of a callout portion of the embodiment of FIG. 1.

FIG. 4 includes a flow diagram including a method of making a nonwovenabrasive article according to an embodiment.

FIG. 5 includes a top view illustration of a zone of inhibition resultof a nonwoven abrasive article according to an embodiment.

FIG. 6A includes a SEM image of a surface portion of an abrasive articleaccording to an embodiment.

FIG. 6B includes a SEM image of an internal portion of an abrasivearticle according to an embodiment.

FIG. 7 includes an image of the results of zone of inhibition testingaccording to an embodiment including 1% triclosan (“TN”) antimicrobialagent against Klebsiella pneumonia (“K. pneumonia”), Escherichia coli(“E. coli”), Bacillus, and Staphylococcus aureus (“S. aureus”).

FIG. 8 includes an image of the results of zone of inhibition testingaccording to an embodiment including 0.5% zinc pyrithione (“ZPT)antimicrobial agent against S. aureus, Bacillus, and E. coli; and 1% ZPTagainst E. coli.

FIG. 9 includes an image of the results of zone of inhibition testingaccording to an embodiment including 1% ZPT antimicrobial agent againstS. aureus and Bacillus; and 1.5% ZPT against E. coli and Bacillus.

FIG. 10 includes an image of the results of zone of inhibition testingaccording to an embodiment including 1% of a 1:1 zinc pyrithione:triclosan mixture (“TNZ”) antimicrobial agent against E. coli, Bacillus,and S. aureus.

FIG. 11 includes an image of the results of zone of inhibition testingaccording to an embodiment including 1.5% of TNZ against E. coli,Bacillus, and S. aureus.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION

FIG. 1 includes an illustration of a perspective view of a nonwovenabrasive article 100 according to an embodiment. In particular, nonwovenabrasive article 100 can include a nonwoven substrate, and moreparticularly can be configured as a scrubber pad useful for cleaning ina moist environment, such as in a kitchen. In an embodiment, a nonwovenabrasive article can have a body having any regular or irregular shape.In an embodiment, a nonwoven abrasive article can have two major sidesopposite each other and generally parallel to each other. In theembodiment illustrated in FIG. 1, the nonwoven abrasive article 100 canhave a generally square or rectangular shape, a first surface 106, asecond surface 108 generally opposite of the first surface 106, and athickness 102 extending from the first surface 106 to the second surface108. According to an embodiment, the nonwoven abrasive article 100 canhave one or more formulations coated, dipped, sprayed, adhered to, orotherwise disposed on one or more of the first surface 106 or the secondsurface 108, and additionally within and throughout the thickness 102.In particular, the one or more formulations can include an antimicrobialagent.

FIG. 2 includes an illustration of a surface view of a callout portion104 of the nonwoven abrasive article 100 of FIG. 1. The nonwovenabrasive article 100 can include a formulation having one or moreantimicrobial agents disposed on the surface of the nonwoven abrasivearticle 100. As illustrated, a formulation 201 including anantimicrobial agent can be coated on portions of an interlocked web 202formed of nonwoven filaments 203.

FIG. 3 includes an illustration of an interior view of the calloutportion 104 of the nonwoven abrasive article 100 of FIG. 1. The nonwovenabrasive article 100 can include a formulation having one or moreantimicrobial agents disposed within and throughout the thickness 102 ofthe nonwoven abrasive article 100, as represented by FIG. 3. Asillustrated, a formulation 301 including one or more antimicrobialagents can be coated on portions of an interlocked web 202 formed ofnonwoven filaments 203. In an embodiment, the formulation 301 disposedwithin and throughout the thickness 102 can be the same or differentfrom the formulation 201 disposed on the one or more surfaces 106, 108of the nonwoven abrasive article 100.

FIG. 4 includes an illustration of a flow diagram for a method of makingan abrasive article having an antimicrobial agent in accordance with anembodiment. Step 401 of FIG. 4 includes preparing a first formulation.In a particular embodiment, a dip coating formulation can be prepared instep 401. In step 402, impregnating the nonwoven substrate material withthe first formulation occurs. In a particular embodiment, theimpregnation is accomplished by dipping the nonwoven substrate materialin the first formulation and squeezing out excess formulation. Step 403,includes preparing a second formulation. In a particular embodiment, aspray formulation can be prepared in step 403. Step 404 includesdisposing the second formulation on a first side of the nonwovensubstrate material. In a particular embodiment, disposing the secondformulation is accomplished by spraying the second formulation. Step 405includes disposing the second formulation on a second side of thenonwoven substrate material. In a particular embodiment, disposing thesecond formulation is accomplished by spraying the second formulation.Step 406 includes curing the substrate to form an abrasive article. In aparticular embodiment, the curing can be accomplished by heating thesaturated nonwoven material substrate in an oven so as to cure the firstformulation and the second formulation.

First Formulation

In an embodiment, a nonwoven substrate material is impregnated with afirst formulation, wherein the first formulation has broad spectrumantimicrobial effectiveness against one or more microbial organisms; andwherein the first formulation comprises a first antimicrobial agent andabrasive particles uniformly dispersed in a first polymer composition.In a particular embodiment, the first formulation has broad spectrumantimicrobial effectiveness against Staphylococcus aureus (also referredto herein as “S. aureus”), and one or more of Klebsiella pneumonia (alsoreferred to herein as “K. pneumonia”), Bacillus, and Escherichia coli(also referred to herein as “E. coli”).

In accordance with an embodiment, the first formulation comprises afirst antimicrobial agent. In a particular embodiment, a firstformulation can be configured as a coating that impregnates the nonwovensubstrate material and adheres to the fibers of the nonwoven substratematerial throughout the thickness of the non-woven material. Asdescribed further herein, the first formulation can be applied in anysuitable manner that impregnates the nonwoven substrate material in aselective or uniform manner throughout the nonwoven material. FIG. 2 andFIG. 6A illustrate a first formulation disposed on (i.e., adhered to)the fibers of the interior of a nonwoven material substrate according toan embodiment.

In accordance with an embodiment, the first formulation comprises afirst antimicrobial agent. The first antimicrobial agent can comprise acompound that has antimicrobial properties as understood by those ofordinary skill in the art, such as the ability to kill (e.g.,bactericidal) or inhibit the growth (e.g., bacteriostatic) ofmicroscopic organisms such as, for example, bacteria, fungi, orprotozoa. Examples of first antimicrobial agents can include triclosan(also referred to herein as “TN”), triclocarban (also referred to hereinas “TCC”), polyhexamethylene, binguanide (also referred to herein as“PHMB”), salicylic acid, benzalkonium chloride, chloroxylenol, silver,pyrithiones, or any combination thereof. A first antimicrobial agent canbe available in one or more formats, such as a solution, a suspension,an emulsion, a sol, a gel, a solid, a powder, a composite, orcombinations thereof. A first antimicrobial agent can be in a suitableparticle size, more particularly micron sized particles, nano sizedparticles, or a combination thereof. In a particular embodiment, thefirst antimicrobial agent can include a pyrithione, and moreparticularly, zinc pyrithione (also referred to herein as “ZPT”). In aparticular embodiment, the first antimicrobial agent can comprise puresilver, elemental silver, ionic silver, or combinations thereof. In aparticular embodiment, the silver can comprise a silver salt. In aspecific embodiment, the silver can be a silver solution, a silversuspension, a silver emulsion, a silver sol, a silver gel, solid silver,a silver powder, a silver composite material, or combinations thereof.In a particular embodiment, the silver can be in combination with apolymer, a polymer composite, or combinations thereof. In a particularembodiment, the first antimicrobial agent can comprise ZPT. In aparticular embodiment, the first antimicrobial agent can consistessentially of ZPT. As used herein, the phrase “consist essentially of,”“consisting essentially of,” “consists essentially of,” or any such anequivalent phrase, limits the scope of the antimicrobial agent to thespecified antimicrobial agent, but the scope can include other materialsthat do not materially affect the characteristic of being anantimicrobial agent as defined herein. In other words, an abrasivearticle according to an embodiment that consists essentially of ZPT doesnot include another antimicrobial agent.

In an embodiment, the first antimicrobial agent can have a broadspectrum effectiveness against one or more microbial organisms. Broadspectrum antimicrobial effectiveness can be defined as capable ofkilling at least 75% of the population of an initial inoculation of oneor more microbial organisms. Alternatively, broad spectrum effectivenessagainst one or microbial organisms can be defined as capable ofproducing a zone of inhibition around a sample of the abrasive article,wherein the zone of inhibition is at least 3 cm for a population of oneor more microbial organisms. In a specific embodiment, a firstantimicrobial agent possesses broad spectrum antimicrobial effectivenesswhen it satisfies either of the definitions of broad spectrumeffectiveness. In a specific embodiment, a first antimicrobial agentpossesses broad spectrum antimicrobial effectiveness when it satisfiesboth definitions of broad spectrum effectiveness.

In a particular embodiment, the first antimicrobial agent can have abroad spectrum antimicrobial effectiveness against S. aureus, and one ormore of K. pneumoniae, Bacillus, and E. coli. Broad spectrumantimicrobial effectiveness can be defined as capable of killing atleast 75% of the population of an initial inoculation of E. coli after24 hours, at least 75% of the population of an initial inoculation of K.pneumoniae after 24 hours, and killing at least 95% of the population ofan initial inoculation of S. aureus after 24 hours in accordance withtest method ASTM: E2149-10. Alternatively, broad spectrum antimicrobialeffectiveness can be defined as capable of producing a zone ofinhibition around a sample of the abrasive article, wherein the zone ofinhibition is at least 3 cm for a population of S. aureus, and one ormore of K. pneumoniae, Bacillus, and E. coli for a 2.54 cm by 2.54 cm(2.54 cm²) abrasive article sample tested according to the Kirby-Bauerantibiotic testing method (also commonly known as KB testing or diskdiffusion antibiotic sensitivity testing. In a specific embodiment, afirst antimicrobial agent possesses broad spectrum antimicrobialeffectiveness when it satisfies either of the definitions of broadspectrum effectiveness. In a specific embodiment, a first antimicrobialagent possesses broad spectrum antimicrobial effectiveness when itsatisfies both definitions of broad spectrum effectiveness.

FIG. 5, illustrates a top view of a bacterial sample 505 containedwithin petri dish 504. Surrounding abrasive article 501 is a zone ofinhibition 502 having a diameter 503 indicating effective antimicrobialproperties of the abrasive article.

The first formulation can include a first antimicrobial agent in aparticular concentration. In an embodiment, the first formulation caninclude a first antimicrobial agent at a concentration of at least 0.1wt % of the total weight of the formulation, such as at a concentrationof at least 0.2 wt %, at least 0.3 wt %, at least 0.4 wt %, at least 0.5wt %, at least 0.6 wt %, at least 0.7 wt %, at least 0.8 wt %, at least0.9 wt %, at least 1.0 wt %, at least 1.1. wt %, at least 1.2 wt %, atleast 1.3 wt %, at least 1.4 wt %, or at least 1.5 wt %. In anon-limiting embodiment, the first formulation can include anantimicrobial agent at a concentration of not greater than 5.0 wt % ofthe total weight of the formulation, such as at a concentration of notgreater than not greater than 4.5 wt %, not greater than 4.0 wt %, notgreater than 3.5 wt %, not greater than 3.0 wt %, not greater than 2.5wt %, not greater than 2.0 wt %, or not greater than 1.5 wt %. It willbe appreciated that the first formulation can include an antimicrobialagent at a concentration within any range of maximum or minimum valuesnoted above, such as within a range of from 0.1 wt % to 5.0 wt %, orwithin a range of from 0.5 wt % to 1.5 wt % of the total weight of thefirst formulation.

In an embodiment, the first formulation comprises the firstantimicrobial agent and abrasive particles uniformly dispersed in afirst polymer composition. In an embodiment, the first polymercomposition can comprise phenolic resin, melamine formaldehyde resin, orcombinations thereof. In a particular embodiment, the phenolic resin isa phenol formaldehyde resin, more particularly the phenolic resin cancomprise a resole resin.

Suitable resole resins can be classified by a number of features, suchas the formaldehyde to phenol ratio (F/P ratio) prior to reaction, freeformaldehyde content (FFC) of the polymer after reaction, free phenolcontent (FPC) after reaction, gel time at a specific temperature, andthe water tolerance of the resin. In an embodiment, the F/P ratio can bein a range of 0.95 to 2.5, such as 0.95 to 1.1, or 1.2 to 1.5, or 1.6 to1.8, or 1.9 to 2.2, or a combination thereof. In an embodiment, the FFCcan be in a range of 0.02% to 3.3% by weight of the resin, such as about0.02% to 0.09%, or 0.2% to 0.45%, or 0.5% to 0.8%, or 1.0% to 1.3%, or2.5% to 3%, or combinations thereof. In an embodiment, the FPC can be ina range of 2% to 5%, or 4% to 7%, or 12% to 15%, or 16% to 20%, orcombinations thereof. In an embodiment, the gel time at 121° C. can bein range of 5 minutes to 30 minutes, such as 7-11 minutes, 8-12 minutes,9-10 minutes, 10-12 minutes, 18-22 minutes, 19-26 minutes, orcombinations thereof. In an embodiment, the water tolerance is in arange of 100% to 600%, such as 100 to 300%, 100 to 350%, 150 to 300%,150 to 350%, 400 to 480%, 400 to 550%, 430 to 500%, or combinationsthereof. In a specific embodiment, a suitable resole resin, alsoreferred to herein as “Type 2” phenolic resin, can comprise an F/P ratioin a range of 1.9 to 2.2, a gel time at 121° C. in a range of 7-11minutes; and a water tolerance in a range of 150 to 300%. In anotherspecific embodiment, a suitable resole resin, also referred to herein as“Type 1” phenolic resin, can comprise an F/P ratio in a range of 1.6 to1.8, a gel time at 121° C. in a range of 8-12 minutes; and a watertolerance in a range of 150 to 300%.

In an embodiment, the first formulation can include a first polymercomposition in a particular concentration. In an embodiment, the firstformulation can include a first polymer composition at a concentrationof at least 10 wt % of the total weight of the first formulation, suchas at a concentration of at least 22 wt %, at least 24 wt %, at least 26wt %, at least 28 wt %, or at least 30 wt %. In a non-limitingembodiment, the first formulation can include a first polymercomposition at a concentration of not greater than 60 wt %, such as notgreater than 45 wt %, not greater than 40 wt %, not greater than 35 wt%, or not greater than 30 wt %. It will be appreciated that the firstformulation can include a first polymer composition at a concentrationwithin any range of maximum or minimum values noted above, such aswithin a range of 20 wt % to 50 wt %, or 30 wt % to 50 wt %, or 30 wt %to 40 wt % of the total weight of the first formulation.

In an embodiment, the first formulation can include a resole resin in aparticular concentration. In an embodiment, the first formulation caninclude a resole resin at a concentration of at least 10 wt % of thetotal weight of the formulation, such as at a concentration of at least22 wt %, at least 24 wt %, or at least 26 wt %. In a non-limitingembodiment, the first formulation can include a resole resin at aconcentration of not greater than 60 wt %, not greater than 50 wt %, notgreater than 40 wt %, not greater than 35 wt %, such as not greater than33%, or not greater than 30 wt %. It will be appreciated that the firstformulation can include a resole resin at a concentration within anyrange of maximum or minimum values noted above, such as within a rangeof 20 wt % to 40 wt %, 20 wt % to 30 wt %, or 25 wt % to 35 wt % of thetotal weight of the first formulation.

In an embodiment, the first formulation can include a melamineformaldehyde resin (melamine resin), such as that commercially availableunder the trade name POLYFIX® from Benson Polymers Ltd, (Delhi, India).

In an embodiment, the first formulation can include a melamineformaldehyde resin in a particular concentration. In an embodiment, thefirst formulation can include a melamine resin at a concentration of atleast 2.0 wt % of the total weight of the formulation, such as at aconcentration of at least 5.0 wt %, at least 7 wt %, at least 8.0 wt %,at least 10 wt %, at least 15 wt %. In a non-limiting embodiment, thefirst formulation can include a melamine resin at a concentration of notgreater than 20.0 wt %, not greater than 15.0 wt %, not greater than 10wt %, not greater than 9 wt %, or not greater than 8.0 wt %. It will beappreciated that the first formulation can include a melamine resin at aconcentration within any range of maximum or minimum values noted above,such as within a range of 7.0 wt % to 10.0 wt %, or within a range of8.0 wt % to 9.0 wt % of the total weight of the first formulation.

A plurality of abrasive particles can be included in the firstformulation. The term abrasive particles, as used herein alsoencompasses abrasive grains, abrasive agglomerates, abrasive aggregates,green-unfired abrasive aggregates, shaped abrasive particles, andcombinations thereof. As described herein, the plurality of abrasiveparticles can be dispersed in a slurry coat of the first formulation.Thus, the abrasive particles can be disposed on the first formulation,be at least partially embedded in the first formulation, or acombination thereof. The abrasive particles can generally have a Mohshardness of greater than about 3, and preferably in a range from about 3to about 10. For particular applications, the abrasive particles canhave a Mohs hardness of at least 5, 6, 7, 8, or 9. In a specificembodiment, the abrasive particles have a Mohs hardness of 9. In anotherspecific embodiment, the abrasive particles have a Mohs hardness of 6.5to 7.5. Suitable abrasive particles include non-metallic, inorganicsolids such as carbides, oxides, nitrides, silicates & aluminosilicatesand certain carbonaceous materials. Oxides can include silicon oxide(such as quartz, cristobalite and glassy forms), cerium oxide, zirconiumoxide, and various forms of aluminum oxide (including fused aluminas,sintered aluminas, seeded and non-seeded sol-gel aluminas). Carbides andnitrides can include silicon carbide, aluminum carbide, aluminumnitride, aluminium oxynitride, boron nitride (including cubic boronnitride), titanium carbide, titanium nitride, and silicon nitride.Carbonaceous materials can include diamond, which broadly includessynthetic diamond, diamond-like carbon, and related carbonaceousmaterials such as fullerite and aggregate diamond nanorods. Suitableabrasive particles can also include a wide range of naturally occurringmined minerals, such as garnet, cristobalite, quartz, corundum,feldspar, or the like, and combinations thereof. In particularembodiments, the abrasive particles can be diamond, silicon carbide,aluminum oxide, cerium oxide, or combinations thereof. Abrasiveparticles can be mixtures of two or more different abrasive particles orcan be a single type of abrasive particle.

In an embodiment, the first formulation can include silica, emery,garnet, aluminum oxide, silicon carbide, or combinations thereof. Theabrasive particles can be of any desired size or shape. In a specificexample, the first formulation can include garnet particles having amesh size of at least #120, or at least #220, at least #240. In anembodiment, garnet particles can include a mesh size of not greater than#400. It will be appreciated that garnet particles can have a mesh sizewithin any minimum or maximum range indicated above, and in a particularembodiment, can include a combination of mesh sizes indicated above. Ina more particular embodiment, the first formulation abrasive particlescan consists essentially of #220 garnet.

In an embodiment, the first formulation can include abrasive particlesin a particular concentration. In an embodiment, the first formulationcan include abrasive particles at a concentration of at least 20.0 wt %of the total weight of the first formulation, such as at a concentrationof at least at least 30 wt %, at least 35 wt %, at least 40 wt %, atleast 50 wt %. In a non-limiting embodiment, the first formulation caninclude abrasive particles at a concentration of not greater than 70 wt%, not greater than 60 wt %, not greater than 50.0 wt %, not greaterthan 45.0 wt %, or not greater than 40 wt %. It will be appreciated thatthe first formulation can include abrasive particles at a concentrationwithin any range of maximum or minimum values noted above. In aparticular embodiment, the second formulation can include abrasiveparticles at a concentration within a range of 40.0 wt % to 30.0 wt % ofthe total weight of the first formulation.

The first formulation can include one or more fillers. The filler can bea single type of filler or a mixture of fillers. The filler can serve toincrease the Young's modulus of the first formulation. The filler canserve to modify the pH of the first formulation. Suitable fillers can besynthetic materials or naturally occurring materials. A filler can be aninorganic or organic material. In a particular embodiment, the firstformulation can include a filler, such as calcium carbonate.

In an embodiment, the first formulation can include a filler in aparticular concentration. In an embodiment, the first formulation caninclude a filler at a concentration of at least 5.0 wt % of the totalweight of the first formulation, such as at a concentration of at least10.0 wt %, at least 15 wt %. In a non-limiting embodiment, the firstformulation can include a filler at a concentration of not greater than30 wt %, not greater than 25 wt %, not greater than 20 wt %, or notgreater than 15.0 wt % of the total weight of the first formulation. Itwill be appreciated that the first formulation can include a filler at aconcentration within any range of maximum or minimum values noted above,such as within a range of 10 wt % to 15 wt % of the total weight of thefirst formulation.

In an embodiment, the first formulation can include water in aparticular concentration. In an embodiment, the first formulation caninclude water at a concentration of at least 2.0 wt % of the totalweight of the first formulation, such as at a concentration of at least4.0 wt %, at least 8.0 wt %, at least 10.0 wt %, at least 12.0 wt %, orat least 13 wt %. In a non-limiting embodiment, the first formulationcan include water at a concentration of not greater than 25 wt %, notgreater than 20.0 wt %, not greater than 18.0 wt %, not greater than16.0 wt %, or not greater than 15.0 wt %. It will be appreciated thatthe first formulation can include water at a concentration within anyrange of maximum or minimum values noted above, such as within a rangeof 10.0 wt % to 20.0 wt %.

As will be appreciated, water can be added to the first formulation toadjust viscosity or for varying concentrations of materials of the firstformulation such as, in an embodiment, changes in the concentration ofthe antimicrobial agent.

The first formulation can also comprise other additives that aid themanufacture of the abrasive article. Other additives can include clays;such as kaolin; salts, pH modifiers, adhesion promoters, thickeners,plasticizers, lubricants, wetting agents, antistatic agents, pigments,dyes, coupling agents; flame retardants, degassing agents, anti-dustingagents, thixotropic agents, rheology modifiers, initiators, surfactants,chain transfer agents, stabilizers, dispersants, reaction mediators,dyes, colorants, and defoamers.

In an embodiment, a first formulation can comprise one or more rheologymodifiers. A rheology modifier can be used to influence the viscosity ofthe polymer binder composition and thus influence the distribution ofthe abrasive particles on the surface of, or throughout the body of, thenonwoven material substrate. In an embodiment, a rheology modifier canbe a single type of rheology modifier or a mixture of rheologymodifiers. In an embodiment, the first formulation can include a wettingagent.

In an embodiment, the wetting agent can be in a particularconcentration. In an embodiment, the first formulation can include awetting agent in a concentration of at least 0.05 wt % of the totalweight of the formulation. In a non-limiting embodiment, the firstformulation can include a wetting agent in a concentration of notgreater than 2.0 wt %, such as not greater than 1.5 wt %, of the totalweight of the first formulation. In will be appreciated that the firstformulation can include a wetting agent at a concentration within anyrange of maximum or minimum values noted above, such as with a range of0.05 wt % to 1.5 wt % of the total weight of the first formulation.

In an embodiment, the first formulation can include a defoamer in aparticular concentration. In an embodiment, the first formulation caninclude a defoamer in a concentration of at least 0.1 wt % of the totalweight of the first formulation, such as at a concentration of at least0.2 wt %. In a non-limiting embodiment, the first formulation caninclude a defoamer at a concentration of not greater than 0.5 wt %, suchas not greater than 0.4 wt %, or not greater than about 0.3 wt %. Inwill be appreciated that the first formulation can include a defoamer ata concentration within any range of maximum or minimum values notedabove, such as with a range of 0.1 wt % to 0.3 wt % of the total weightof the first formulation.

In an embodiment, the first formulation can include a pigment. In aparticular embodiment, the pigment can include a green pigment. In anembodiment, the first formulation can include a pigment in a particularconcentration. In an embodiment, the first formulation can include apigment in a concentration of at least 0.1 wt % of the total weight ofthe formulation, such as at least 0.3 wt %. In a non-limitingembodiment, the first formulation can include a wetting agent in aconcentration of not greater than 2.0 wt %, not greater than 1.0 wt %,or not greater than 0.7 wt % of the total weight of the firstformulation. In will be appreciated that the first formulation caninclude a pigment in a concentration within any range of maximum orminimum values noted above, such as with a range of 0.3 wt % to 0.7 wt %of the total weight of the first formulation.

Second Formulation

In an embodiment, a nonwoven substrate material is impregnated with asecond formulation, wherein the second formulation has broad spectrumantimicrobial effectiveness against one or more microbial organisms; andwherein the second formulation comprises a second antimicrobial agentand abrasive particles uniformly dispersed in a second polymercomposition. In a particular embodiment, the second formulation hasbroad spectrum antimicrobial effectiveness against S. aureus, and one ormore of K. pneumoniae, Bacillus, and E. coli.

In accordance with an embodiment, the abrasive article can comprise asecond formulation, alone or in combination with the first formulation.In a particular embodiment, the second formulation can be configured asa coating that is applied to and adheres the fibers of the exteriorsurfaces (e.g., a first side and/or a second side) of a non-wovenmaterial. In a more particular embodiment, the second formulation can beconfigured to be a spray coating. As will be appreciated, the secondformulation can penetrate into the body of the nonwoven substratematerial, and can even saturate the nonwoven substrate material ifsupplied in sufficient quantities. FIG. 3 and FIG. 6B illustrate asecond formulation disposed on (i.e., adhered to) the fibers on anexterior surface (i.e., on a side) of a nonwoven material substrateaccording to an embodiment.

In accordance with an embodiment, the second formulation can include asecond antimicrobial agent. The second antimicrobial agent can be thesame as or different from than the first antimicrobial agent included inthe first formulation. The second antimicrobial agent can comprise acompound that has antimicrobial properties as understood by those ofordinary skill in the art, such as the ability to kill (e.g.,bactericidal) or inhibit the growth (e.g., bacteriostatic) ofmicroscopic organisms such as, for example, bacteria or fungi. Examplesof second antimicrobial agents can include triclosan (also referred toherein as “TN”), triclocarban (also referred to herein as “TCC”),polyhexamethylene, binguanide (also referred to herein as “PHMB”),salicylic acid, benzalkonium chloride, chloroxylenol, silver,pyrithiones, or any combination thereof. A second antimicrobial agentcan be available in one or more formats, such as a solution, asuspension, an emulsion, a sol, a gel, a solid, a powder, a composite,or combinations thereof. A second antimicrobial agent can be in asuitable particle size, more particularly micron sized particles, nanosized particles, or a combination thereof. In a particular embodiment,the second antimicrobial agent can include a pyrithione, and moreparticularly, zinc pyrithione (ZPT). In a particular embodiment, thesecond antimicrobial agent can comprise pure silver, elemental silver,ionic silver, or combinations thereof. In a particular embodiment, thesilver can comprise a silver salt. In a specific embodiment, the silvercan be a silver solution, a silver suspension, a silver emulsion, asilver sol, a silver gel, solid silver, a silver powder, a silvercomposite material, or combinations thereof. In a particular embodiment,the silver can be in combination with a polymer, a polymer composite, orcombinations thereof. In a particular embodiment, the secondantimicrobial agent can include a pyrithione, and more particularly,zinc pyrithione (also referred to herein as “ZPT”). In a particularembodiment, the second antimicrobial agent can comprise ZPT. In aparticular embodiment, the second antimicrobial agent can consistessentially of ZPT. As used herein, the phrase “consist essentially of,”“consisting essentially of,” “consists essentially of,” or any such anequivalent phrase, limits the scope of the antimicrobial agent to thespecified antimicrobial agent, but the scope can include other materialsthat do not materially affect the characteristic of being anantimicrobial agent as defined herein. In other words, an abrasivearticle according to an embodiment that consists essentially of ZPT doesnot include another antimicrobial agent.

The second antimicrobial agent can have broad spectrum antimicrobialeffectiveness against one or more microbial organisms as defined abovewith respect to the first antimicrobial agent.

The second antimicrobial agent can have broad spectrum antimicrobialeffectiveness against S. aureus, and one or more of K. pneumoniae,Bacillus, and E. coli as defined above with respect to the firstantimicrobial agent.

The second formulation can include a second antimicrobial agent in aparticular concentration. In an embodiment, the second formulation caninclude a second antimicrobial agent at a concentration of at least 0.1wt % of the total weight of the formulation, such as at a concentrationof at least 0.2 wt %, at least 0.3 wt %, at least 0.4 wt %, at least 0.5wt %, at least 0.6 wt %, at least 0.7 wt %, at least 0.8 wt %, at least0.9 wt %, at least 1.0 wt %, at least 1.1. wt %, at least 1.2 wt %, atleast 1.3 wt %, at least 1.4 wt %, or at least 1.5 wt %. In anon-limiting embodiment, the second formulation can include anantimicrobial agent at a concentration of not greater than 5.0 wt % ofthe total weight of the formulation, such as at a concentration of notgreater than not greater than 4.5 wt %, not greater than 4.0 wt %, notgreater than 3.5 wt %, not greater than 3.0 wt %, not greater than 2.5wt %, not greater than 2.0 wt %, or not greater than 1.5 wt %. It willbe appreciated that the second formulation can include an antimicrobialagent at a concentration within any range of maximum or minimum valuesnoted above, such as within a range of from 0.1 wt % to 5.0 wt %, orwithin a range of from 0.5 wt % to 1.5 wt % of the total weight of thesecond formulation.

In an embodiment, the second formulation comprises the secondantimicrobial agent and abrasive particles uniformly dispersed in asecond polymer composition. In an embodiment, the second polymercomposition can comprise phenolic resin. The phenolic resin can be thesame as or different from the phenolic resin of the first formulation.In a particular embodiment, the phenolic resin is a phenol formaldehyderesin, more particularly the phenolic resin can comprise a resole resin.The resole resin can be the same as or different from the resole resinof the first formulation. In a particular embodiment, the resole resinis the same as in the first formulation.

In an embodiment, the second formulation can include a resole resin in aparticular concentration. In an embodiment, the second formulation caninclude a resole resin at a concentration of at least 10 wt % of thetotal weight of the formulation, such as at a concentration of at least20 wt %, at least 24 wt %, or at least 26 wt %. In a non-limitingembodiment, the second formulation can include a resole resin at aconcentration of not greater than 60 wt %, not greater than 50 wt %, notgreater than 40 wt %, not greater than 35 wt % or not greater than 30 wt%. It will be appreciated that the second formulation can include aresole resin at a concentration within any range of maximum or minimumvalues noted above, such as within a range of 20 wt % to 40 wt %, 20 wt% to 30 wt %, or 25 wt % to 35 wt % of the total weight of the secondformulation.

A plurality of abrasive particles, such as described above with respectto the first formulation, can be included in the second formulation. Theabrasive particles can be the same as or different from the abrasiveparticles included in the first formulation. In an embodiment, thesecond formulation can include silica, emery, garnet, aluminum oxide,silicon carbide, or combinations thereof. The abrasive particles can beof any desired size or shape. In an embodiment, the second formulationcan include garnet particles having a mesh of at least #120, or at least#220, at least #240. In an embodiment, garnet particles can include amesh of not greater than #400. It will be appreciated that garnetparticles can have a mesh size within any minimum or maximum rangeindicated above. In a particular embodiment, the second formulationabrasive particles can consists essentially of #240 aluminum oxide.

In an embodiment, the second formulation can include abrasive particlesin a particular concentration. In an embodiment, the second formulationcan include abrasive particles at a concentration of at least 20.0 wt %of the total weight of the second formulation, such as at aconcentration of at least at least 30 wt %, at least 35 wt %, at least40 wt %, at least 50 wt %. In a non-limiting embodiment, the secondformulation can include abrasive particles at a concentration of notgreater than 70 wt %, not greater than 60 wt %, not greater than 50.0 wt%, not greater than 45.0 wt %, or not greater than 40 wt %. It will beappreciated that the second formulation can include abrasive particlesat a concentration within any range of maximum or minimum values notedabove. In a particular embodiment, the second formulation can includeabrasive particles at a concentration within a range of 55.0 wt % to45.0 wt % of the total weight of the second formulation.

In an embodiment the second formulation can include any of the one ormore fillers, water, or other additives, such as rheology modifiers,defoamers, or pigments as described above with respect to the firstformulation.

In an embodiment, the second formulation can include a filler, such ascalcium carbonate. In an embodiment, the second formulation can includea filler in a particular concentration. In an embodiment, the secondformulation can include a filler at a concentration of at least 5.0 wt %of the total weight of the formulation, such as at a concentration of atleast 10.0 wt %. In a non-limiting embodiment, the second formulationcan include a filler at a concentration of 30 wt %, not greater than 25wt %, not greater than 20 wt %, or not greater than 15.0 wt % of thetotal weight of the second formulation. It will be appreciated that thesecond formulation can include a filler at a concentration within anyrange of maximum or minimum values noted above, such as within a rangeof 10 wt % to 15 wt % of the total weight of the second formulation.

In an embodiment, the second formulation can include water in aparticular concentration. In an embodiment, the second formulation caninclude water at a concentration of at least 2.0 wt % of the totalweight of the formulation, such as at a concentration of at least 4.0 wt%, at least 8.0 wt %, at least 10.0 wt %, at least 12 wt %, or at least13 wt %. In a non-limiting embodiment, the second formulation caninclude water at a concentration of not greater than 25 wt %, notgreater than 20.0 wt %, or not greater than 15.0 wt %. It will beappreciated that the second formulation can include an antimicrobialagent at a concentration within any range of maximum or minimum valuesnoted above, such as within a range of 10.0 wt % to 20.0 wt %.

As will be appreciated, water can be added to the second formulation toadjust for viscosity or for varying concentrations of materials of thesecond formulation such as, for example, changes in the concentration ofthe antimicrobial agent.

In an embodiment, the second formulation can include a wetting agent. Inan embodiment, the second formulation can include a wetting agent in aparticular concentration. In an embodiment, the second formulation caninclude a wetting agent in a concentration of at least 0.05 wt % of thetotal weight of the formulation. In a non-limiting embodiment, thesecond formulation can include a wetting agent in a concentration of notgreater than 2.0 wt %, or not greater than 1.5 wt %, of the total weightof the second formulation. In will be appreciated that the secondformulation can include a wetting agent at a concentration within anyrange of maximum or minimum values noted above, such as with a range of0.05 wt % to 1.5 wt % of the total weight of the second formulation.

In an embodiment, the second formulation can include a defoamer in aparticular concentration. In an embodiment, the second formulation caninclude a defoamer in a concentration of at least 0.1 wt % of the totalweight of the formulation, such as at a concentration of at least 0.2 wt%. In a non-limiting embodiment, the second formulation can include adefoamer at a concentration of not greater than 0.5 wt %, such as notgreater than 0.4 wt %, or not greater than about 0.3 wt %. In will beappreciated that the second formulation can include a defoamer at aconcentration within any range of maximum or minimum values noted above,such as with a range of 0.1 wt % to 0.3 wt % of the total weight of thesecond formulation.

In an embodiment, the second formulation can include a pigment. In aparticular embodiment, the pigment can include a green pigment. In anembodiment, the second formulation can include a pigment in a particularconcentration. In an embodiment, the second formulation can include apigment in a concentration of at least 0.1 wt % of the total weight ofthe formulation, such as at least 0.3 wt %. In a non-limitingembodiment, the second formulation can include a wetting agent in aconcentration of not greater than 2.0 wt %, not greater than 1.0 wt %,or not greater than 0.7 wt % of the total weight of the secondformulation. In will be appreciated that the second formulation caninclude a pigment in a concentration within any range of maximum orminimum values noted above, such as with a range of 0.3 wt % to 0.7 wt %of the total weight of the second formulation.

Nonwoven Substrate Material

Referring back to FIG. 4, step 402 includes impregnating a nonwovensubstrate material with the first formulation. A suitable nonwovensubstrate material, such as for a scrubber pad, can be formed to have aparticular shape. In an embodiment, the nonwoven substrate material canbe in the form of a roll or a sheet, and can be cut to be a regularshape, such as round, oval, square, or can be cut to be an irregularshape, or combinations thereof. In a particular embodiment, the nonwovensubstrate material can have a square shape, and more particularly arectangular shape. In a particular embodiment, the nonwoven substratematerial can be formed into a substrate for a scrubber pad, such as akitchen scrubber pad.

The nonwoven substrate material can comprise a synthetic material, anatural material, or combinations thereof. The material can be anabsorbent material, a nonabsorbent material, or combinations thereof. Inan embodiment, the nonwoven material can include different variety ofaliphatic and aromatic polyamide i.e., nylons and different variety ofaliphatic and aromatic polyesters, or a combination thereof.

The nonwoven substrate can be of any desired weight. In a particularembodiment, the weight of the nonwoven substrate material per unit areacan be in a range of about 100 GSM to 500 GSM, such as 150 GSM to 200GSM, or about 160 GSM to about 180 GSM (i.e., grams per square meter, org/m²). Suitable nonwoven substrates are comprised of fibers that arebound together by various methods or mechanisms, such as typically, bybeing sprayed with a binder formulation. A suitable non-limiting bindercomposition is shown below in Table A of the Examples. The nonwovensubstrate material can have any desired suitable loft. In a specificembodiment the loft is 12-14 mm and a weight per unit area within arange of 230-250 GSM. In accordance with an embodiment, the nonwovensubstrate material can include one or more binders to adhere andinterlock the threads (fibers) of the nonwoven web. In a particularembodiment, the binder can include natural or synthetic rubber latex, alarge range of acrylic binder, melamine formaldehyde resin, or acombination thereof. The nonwoven substrate material is cured andcomplete prior to application of the first formulation or the secondformulation.

In an embodiment, the nonwoven substrate material can have a particularthickness. Thickness can be defined as the minimum exterior dimension ofthe nonwoven substrate material. In an embodiment, the nonwovensubstrate material can have a thickness that is at least 1 mm, such asat least 5 mm, at least 10 mm, at least 15 mm, at least 20 mm, or evenat least 25 mm. In a non-limiting embodiment, the nonwoven substratematerial can have a thickness that is not greater than 100 mm, such asnot greater than 50 mm, or even not greater than 30 mm. It will beappreciated that the nonwoven substrate material can have a thicknessthat is within a range of any minimum or maximum value noted above.

In an embodiment, the nonwoven substrate material can have a particularloft. In an embodiment, the nonwoven substrate material can have a loftof at least 5 mm, such as at least 8 mm, or at least 10 mm. In anon-limiting embodiment, the nonwoven substrate material can have a loftthat is not greater than 35 mm, such as not greater than 30 mm, notgreater than 20 mm, not greater than 15 mm, or even not greater than 12mm. It will be appreciated that the nonwoven substrate material can havea loft that is within a range of any maximum or minimum value notedabove, such as within a range of 8 mm to 14 mm.

In an embodiment, the nonwoven substrate material can have a particularweight per unit area, defined as grams per square meter, or GSM. In anembodiment, the nonwoven substrate material can have a weight of atleast 200 GSM, such as at least 220 GSM, or at least 240 GSM. In anon-limiting embodiment, the nonwoven substrate material can have aweight per unit area of not greater than 300 GSM, such as not greaterthan 270 GSM, or even not greater than 250 GSM. It will be appreciatedthat the nonwoven substrate material can have a weight per unit areawithin a range of any minimum or maximum value noted above, such aswithin a range of 240 GSM to 250 GSM.

Method of Making

Referring back to FIG. 4, step 401 includes preparing the firstformulation. The ingredients of the first formulation, as describedabove can, can be mixed together by any suitable means (e.g., high-shearor low shear mixer) to prepare the first formulation.

Step 402 includes impregnating the nonwoven substrate material with thefirst formulation. The impregnation can be accomplished by any suitablemeans or manner that applies a sufficient amount of the firstformulation so that the nonwoven substrate material becomes thoroughlysoaked with the first formulation. In an embodiment, the impregnationcan be accomplished by dipping, spraying, submerging, coating, orwashing the nonwoven substrate material with or in the firstformulation, or combinations thereof. The impregnation can occur as asingle step or multiple steps, such as multiple dipping steps ormultiple spraying steps of the nonwoven substrate material, orcombinations thereof. In a specific embodiment, the nonwoven fabric isdipped into the first formulation. In another embodiment, the nonwovensubstrate material is sprayed with the first formulation.

Optionally, (not shown) the amount of formulation the substrate materialis impregnated with can be adjusted. Adjusting the saturation of thefirst formulation can be accomplished by any method or mechanism thatdoes not overly degrade the nonwoven substrate material, such aspressing, squeezing, brushing, squeegeeing, blowing, dabbing, blotting,rollering, shaking, or combinations thereof, and the like. In a specificembodiment, the impregnated nonwoven substrate material can be squeezed,such as between a pair of rollers to adjust the saturation of theimpregnated nonwoven substrate material. During step 402, in anembodiment, the nonwoven substrate material can be impregnated with aspecific amount of uncured first formulation. In an embodiment, thenonwoven substrate can be impregnated with at least 200 GSM, at least300 GSM, at least 400 GSM, at least 500 GSM, at least 600 GSM, or atleast 700 GSM of the first formulation. In a non-limiting embodiment,the nonwoven substrate material is impregnated with not greater than2000 GSM, not greater than 1500 GSM, not greater than 1000 GSM, notgreater than 800 GSM, not greater than 700 GSM, or not greater than 600GSM of the first formulation. It will be appreciated that the nonwovensubstrate material can be impregnated with a weight of the firstformulation within any range of minimum or maximum values noted above.In a particular embodiment, the nonwoven substrate material can beimpregnated with a weight of the first formulation ranging from 200 GSMto 2000 GSM.

Referring back to FIG. 4, step 403 includes preparing the secondformulation. The ingredients of the second formulation, as describedabove, can be mixed together by any suitable means to form the secondformulation.

Post Step 402 operation, Step 404 includes disposing the secondformulation on a first side of the nonwoven substrate material. Step 405includes disposing the second formulation on a second side of thenonwoven substrate material. Steps 404 and 405, similar to step 402, canbe accomplished by any suitable method, such as dipping, spraying,submerging, coating, or washing the nonwoven substrate material with orin the first formulation, or combinations thereof. In a specificembodiment, step 404 and step 405 are accomplished by spraying thenonwoven substrate material with the second formulation.

During step 404, in an embodiment, a particular amount of secondformulation can be disposed on the first side of the nonwoven substratematerial. In a non-limiting embodiment, at least 100 GSM, such as atleast 125 GSM, such as at least 150 GSM, such as at least 175 GSM, atleast 200 GSM, at least 500 GSM, or at least 750 GSM of the secondformulation can be disposed on the first side of the nonwoven substratematerial. In a non-limiting embodiment, not greater than 1000 GSM, suchas not greater than 750 GSM, not greater than 500 GSM, not greater than350 GSM, not greater than 325 GSM, not greater than 300 GSM, not greaterthan 275 GSM, not greater than 250 GSM, or not greater than 200 GSM ofthe second formulation can be disposed on the first side of the nonwovensubstrate material. It will be appreciated that the amount of secondformulation disposed on the first side of the nonwoven substratematerial can be within any range of minimum or maximum values notedabove. In a particular embodiment, the amount of second formulationdisposed on the first side of the nonwoven substrate material can berange from 100 GSM to 300 GSM.

During step 405, in an embodiment, a particular amount of uncured secondformulation can be disposed on the second side of the nonwoven substratematerial. In a non-limiting embodiment, at least 100 GSM, such as atleast 125 GSM, at least 150 GSM, at least 175 GSM, at least 200 GSM, atleast 500 GSM, or at least 750 GSM of the second formulation can bedisposed on the second side of the nonwoven substrate material. In anon-limiting embodiment, not greater than 1000 GSM, such as not greaterthan 750 GSM, not greater than 500 GSM, not greater than 350 GSM notgreater than 325 GSM, not greater than 300 GSM, not greater than 275GSM, not greater than 250 GSM, or not greater than 200 GSM of the secondformulation can be disposed on the second side of the nonwoven substratematerial. It will be appreciated that the amount of second formulationdisposed on the second side of the nonwoven substrate material can bewithin any range of minimum or maximum values noted above. In aparticular embodiment, the amount of second formulation disposed on thesecond side of the nonwoven substrate material can be range from 100 GSMto 300 GSM.

Step 406 includes curing the nonwoven substrate material. Curing can beperformed by any curing process known in the art. In a particularembodiment, curing can include passing the dip-coated and/orspray-coated web though an oven at a temperature that will sufficientlycure the first formulation and/or the second formulation, but that willnot destroy the efficacy of the first or second antimicrobial agent(s).In a particular embodiment, the nonwoven substrate material can be curedat an ambient temperature of 120-160° C.

Abrasive Article

In accordance with an embodiment, the abrasive article provides abrasiveperformance and broad spectrum antimicrobial effectiveness against S.aureus, and one or more of K. pneumoniae, Bacillus, and E. coli asdefined above with respect to the first antimicrobial agent.

Surprisingly, the broad spectrum antimicrobial effectiveness lasts overan extended period of time and/or extensive usage of the abrasivearticle. In an embodiment, the abrasive article possesses broad spectrumeffectiveness even after extensive usage, such as even after completing5000 cycles according to the Cyclic Abrasion Test, which equates tocleaning approximately 500 utensils or approximately 15 days of cleaningwith the abrasive article. The Cyclic Abrasion Test is described ingreater detail below in the Examples. Further, the abrasive articlepossesses broad spectrum effectiveness even after being subjected tothree hours of ball milling according to the Accelerated Life Test,which is described in greater detail below in the Examples.

In an embodiment, the abrasive article can have a particular weight,defined as grams per square meter, or GSM. In an embodiment, theabrasive article can have a weight of at least at least 300 GSM, atleast 500 GSM, at least 750 GSM, at least 850 GSM, or at least 1050 GSM.In a non-limiting embodiment, the abrasive article can have a weight ofnot greater than 3000 GSM, such as not greater than 2000 GSM, notgreater than 1500 GSM, or not greater than 1300 GSM. It will beappreciated that the abrasive article can have a weight within a rangeof any minimum or maximum value noted above, such as within a range of300 GSM to 3000 GSM. IN a particular embodiment, the abrasive can have aweight per unit area within a range of 1050 GSM to 1150 GSM.

The completed abrasive article can have a particular measure of nonwovensubstrate material compared to the total weight of the abrasive article(which includes the combined amount of cured first formulation and curedsecond formulation disposed on and in the nonwoven substrate material).In accordance with an embodiment, the abrasive article can have aGSM_(ratio) of the weight of the nonwoven substrate material prior tobeing impregnated and sprayed with the first ad second formulation(GSM_(nonwoven)) to the weight of the final cured abrasive article(GSM_(final)). In an embodiment, the abrasive article can have a GSMratio (i.e., GSM_(nonwoven):GSM_(final)) of at least 1:2, meaning thatthe weight in GSM of the final cured abrasive article has at least twicea much weight as the nonwoven substrate material from which it wasformed. In an embodiment, the GSM_(ratio) can be at least 1:3, at least1:4, or at least 1:5. In a non-limiting embodiment, the GSM_(ratio) canbe not greater than 1:15, such as not greater than 1:6, or not greaterthan 1:5. It will be appreciated that the GSM_(ratio) can be within arange of any minimum or maximum value noted above. In a particularembodiment, the GSM_(ratio) can be within a range of 1:3 to 1:6, andmore particularly within a range of 1:4 to 1:5.

EXAMPLES Example 1—Preparation of an Abrasive Article (“Scrubber Pad”)

A. Non Woven Substrate Material

Several samples of nonwoven substrate material (also called herein“nonwoven substrates”) were obtained for forming inventive abrasivearticles (abrasive scrubber pads). The nonwoven substrates were formedof 100% nylon interlocked web formed by a needling procedure using 0-15mm penetration at a rate of about 10-50 stokes per unit area. The fiberof the nonwoven substrates had fiber weight in a range of about 100 GSMto about 300 GSM (i.e., grams per square meter, or g/m²) as measuredafter the needling procedure. The nonwoven substrates were then sprayedwith a binder formulation shown below in Table A. The web was then curedin an oven at about 150° C. to form the cured nonwoven substrates. Thecured nonwoven substrates had a loft within a range of 12-14 mm and aweight within a range of 230-250 GSM.

TABLE A Backing Resin Formulation Material % Acrylic Latex 45 MelamineFormaldehyde Resin 3 Catalyst 700 0.2 Wetting Agent 0.1 Defoaming Agent0.1 Green Pigment 0.5 Water 51.1B. Impregnation with First Formulation (Zinc Pyrithione (ZPT))

Inventive abrasive article samples were prepared using the nonwovensubstrate material of part A, above, by subsequently dipping thenonwoven substrate material into a vat containing the first formulationas a dip coating (referred to hereinafter as the “dip coating”) to forma dip-coated web. The dip coating formulation included anti-microbialagent zinc pyrithione (ZPT). Samples were prepared using dip coatingshaving 0.5 wt %, 1.0 wt %, and 1.5 wt % of ZPT as the firstantimicrobial agent. The dip coating formulation is shown below in TableB for samples having ZPT concentrations of 1.5 wt %. Note that water wasadded part by part to adjust the viscosity of the final formulation to anumber: B5 Ford viscosity cup at room temperature for 20-30 seconds andto adjust for the different concentrations of ZPT.

TABLE B ZPT Dip Coating Formulation Material wt % Water 4.5 PhenolFormaldehyde Resin 26.9 Melamine Formaldehyde Resin 8.2 Defoaming Agent0.2 Wetting Agent 0.1 Green Pigment 0.5 Dura/Calcium Carbonate 11.5 #220Garnet 37.6 ZPT 1.5-0.5 Water  9.0-10.0C. Application of Second Formulation (Zinc Pyrithione (ZPT))

The ZPT Samples were then sprayed on both the front and back surfaceswith the second formulation as a spray coating (referred to hereinafteras the “spray coating”). Samples were prepared using corresponding spraycoatings having 0.5 wt %, 1.0 wt %, and 1.5 wt % of ZPT as the secondantimicrobial agent. Thus, the webs were dip coated and spray coatedwith matching amounts of antimicrobial agent (e.g., 0.5 wt % ZPT in dipcoat and 0.5 wt % in spray coat). The 0.5 wt % ZPT spray coatingformulation is shown below in Table C. Note that water was added part bypart to adjust the viscosity of the final formulation to a Ford Cup No:5 at room temperature for 20-30 seconds.

TABLE C ZPT Spray Formulation Material wt % Water 4.0 PhenolFormaldehyde Resin 25.0 Defoaming Agent 0.2 Wetting Agent 0.1 GreenPigment 0.5 Dura/Calcium Carbonate 10.0 #240 Aluminum Oxide 50.0 ZPT1.5-0.5 Water 8.7-9.7

The dip-and-spray-coated web was cured in an oven at about 120-160° C.to form cured completed inventive abrasive article sample containing ZPTas the first antimicrobial agent and as the second antimicrobial agent(referred to hereafter as “ZPT samples”). The ZPT samples each had afinal loft of about 11 mm (±1 mm), and a final weight of about 1050 GSM(±50 GSM).

D. Comparative Triclosan (TN) Samples

Comparative samples were prepared by following the same procedure andmaterials as above except that 1.5 wt % Triclosan (TN) was used as thefirst antimicrobial agent in first formulation dip coating and thesecond antimicrobial agent in the second formulation spray coating.

E. Combined Zinc Pyrithione and Triclosan (TNZ) Samples

Comparative samples were prepared by following the same procedure andmaterials as above except that 1.5 wt % of a mixture of zinc pyrithione(ZPT) and Triclosan (TN) in a 1:1 ratio was used as the firstantimicrobial agent in the first formulation dip coating and as thesecond antimicrobial agent in the second formulation spray coating.

F. Zone of Inhibition Test

The inventive zinc pyrithione (ZPT) samples, comparative Triclosan (TN)samples, and comparative 1:1 zinc pyrithione: triclosan mixture (TNZ)samples were evaluated for broad spectrum antimicrobial activity withrespect to organisms S. aureus, K. pneumonia, E. coli, and Bacillusaccording to the well known Kirby-Bauer antibiotic testing method. Allsamples were cut to the same size (approximately 1 in² (˜2.54 cm²)) andeach sample was placed in separate petri dishes upon a substrateinoculated with a particular microbial organism. After 24 hours, thesamples were observed to determine the average diameter of any existingzone of inhibition. The results are indicated below for inventive ZPTsamples, comparative (TN) samples, and the comparative (TNZ) samples, inTables H, I, and J, respectively. FIG. 7 shows zone of inhibitiontesting results for 1% TN against K. pneumonia, E. coli, Bacillus, andS. aureus. FIG. 8 shows zone of inhibition testing results for 0.5% ZPTagainst S. aureus, Bacillus, and E. coli; and 1% ZPT against E. coli.FIG. 9 shows zone of inhibition testing results for 1% ZPT against S.aureus and Bacillus; and 1.5% ZPT against E. coli and Bacillus. FIG. 10shows zone of inhibition testing results for 1% TNZ against E. coli,Bacillus, and S. aureus. FIG. 11 shows zone of inhibition testingresults for 1.5% TNZ against E. coli, Bacillus, and S. aureus.

TABLE H ZPT Zone of Inhibiition E. coli S. aureus Bacillus K. pneumoniaAverage Zone of Inhibition Active Concentration (diameter in cm) Zinc0.50 wt % Reduced 4.43 5.16 Negative Pyrithione growth (ZPT)  1.0 wt %3.9 4.43 4.2 4.43  1.5 wt % 3.53 4.6 4.2 4.0

TABLE I TN Zone of Inhibition E. coli S. aureus Bacillus K. pneumoniaConcen- Average Zone of Inhibition Active tration (diameter in cm)Triclosan 0.50 wt % Negative Negative Negative Negative (TN)  1.0 wt %Negative 7.5 Negative Negative  1.5 wt % Negative Reduced 5.5 Reducedgrowth growth

TABLE J TNZ Zone of Inhibition E. coli S. aureus Bacillus K. pneumoniaConcen- Average Zone of Inhibition Active tration (diameter in cm)Triclosan 0.50 wt % Negative Negative Negative — and Zinc  1.0 wt %Negative Negative 3.6 — Pyrithione  1.5 wt % Reduced 7.0 Reduced Reduced(TNZ) growth growth growth

As illustrated in Tables H, I, and J, and shown in FIG. 7-11, the 1.5 wt% zinc pyrithione (ZPT) samples demonstrated excellent broad spectruminhibition, while the (TN) samples and the (TNZ) samples did not. TableI, surprisingly illustrates that samples having triclosan (TN) as theironly antimicrobial agent: at 0.5 wt % concentration had no antimicrobialactivity; at 1.0 wt % concentration provided only positive inhibition ofS. aureus; and at 1.5 wt % had measurable positive inhibition ofBacillus but only reduced growth of S. aureus and K. pneumoniae. Theterm “reduced growth” as used herein indicates that a clearlydistinguishable circular zone of inhibition was not visible or that thedistribution of the zone of inhibition was sporadic or uneven (from atop view of the area surrounding the sample in the petri dish) such thata uniform diameter zone of inhibition measurement could not bedetermined. More surprisingly, Table J illustrates that theantimicrobial mixture TNZ samples had the poorest results, mostlyindicating negative inhibition at all concentrations.

G. Cyclic Abrasion Test

Additional samples were prepared as above. One sample was preparedhaving 1.5 wt % triclosan (TN). One sample was prepared having 1.0 wt %zinc pyrithione (ZPT) and one sample was prepared having 1.5 wt % ZPT.The samples were subjected to a cyclic abrasion test, which simulatesthe cleaning of an extensive number of kitchen utensils over an extendedperiod of time, and the samples were then tested for antimicrobialinhibition according to the zone of inhibition test discussed above inorder to determine whether the samples retained any antimicrobialproperties. The cyclic abrasion test included scrubbing a 3 in²(corresponding to 7.62 cm²) sample pads against an aluminum surfaceunder a 2 kg load. All the data corresponds to the machine direction andthe non-needled side of each sample. In cyclic abrasion testing for cutrates (CUT), the CUT was measured as the total amount of materialremoved from the aluminum surface during the test. In cyclic abrasiontesting for grinding ratio, the grinding ratio (GR) was measured by theformula GR=CUT/SHED, where SHED=the amount of weight loss of the sampleby the test process. The CUT, SHED, and GR data are obtained from asingle test.

The results of the cyclic abrasion test are illustrated below in TableK.

TABLE K Cyclic Abrasion Test Active E. coli S. aureus Bacillus K.pneumonia agent Cycles Average Zone of Inhibition (cm) TN-1.5% 1000cycles — Reduced — 3.5 growth 2000 cycles — Reduced — 3.3 growth 3000cycles — Reduced — 3.3 growth 5000 cycles — Reduced — 3.16 growthZPT-1.0% 5000 cycles — 4.55 — 3.6 ZPT-1.5% 5000 cycles — 4.66 — 3.6

The results of the cyclic abrasion test indicate that the triclosan (TN)sample retained antimicrobial effectiveness after 5000 cycles onlyagainst K. pneumoniae. However, the inventive zinc pyrithione (ZPT)samples, at concentrations of 1.0% and 1.5%, still retained substantialantimicrobial effectiveness even after 5000 cycles against both S.aureus and K. pneumonia. The “-” (i.e., dash) indicates that noexperiment was performed.

H. Accelerated Life Test

Two additional ZPT samples were prepared, one at a concentration of 1.0wt %, and one at a concentration of 1.5 wt %. The ZPT samples weresubjected to an accelerated life test to simulate real-time scrubbingand subsequently tested for antimicrobial inhibition according to thezone of inhibition test discussed above in order to determine theantimicrobial characteristics of the samples after a predeterminedperiod of simulated use of the samples. The accelerated life testincluded placing a 1 in² (corresponding to 2.54 cm²) sample into acontainer having a soap solution and subjecting the sample to a ballmilling procedure for 3 hours.

The results of the accelerated life test are illustrated below in TableL.

TABLE L Accelerated Life Test Active E. coli S. aureus Bacillus K.pneumonia agent Hours Average Zone of Inhibition (cm) ZPT-1.0% 3 hours —5.2 4.8 4.3 ZPT-1.5% 3 hours — 4.3 5.06 4.3

The results of the accelerated life test indicate that the inventive 1.0wt % and 1.5 wt % ZPT samples still had substantial antimicrobialeffectiveness against S. aureus, Bacillus and K. pneumonia even afterthe 3 hours of ball milling.

I. Antimicrobial Activity—ASTM: E2149-10—ZPT—Virgin Sample

Antimicrobial testing of an inventive ZPT abrasive article sample wasconducted according to ASTM: E2149-10. In particular, the sample usedwas a virgin sample (i.e., a new sample not yet subjected to washing orother cleaning procedures). The results are provided below.

No. of Bacteria per sample (CFU/ml) Inoculated Inoculated PercentageTreated Treated reduction Sample at Sample at of Sample Test 0 hrs. 24hrs. Bacteria Identification Organism (B) (A) (R) ZPT S. aureus 1.85 ×10⁵ <10 >99.99 (1.5 wt %) E. coli 2.10 × 10⁵ 5.8 × 10² 99.72 Virgin K.pneumoniae 1.75 × 10⁵ 4.6 × 10² 99.73 Sample (R) = 100 (B − A/B)

The test results indicate that the inventive samples had broad spectrumantimicrobial effectiveness against S. aureus, E. coli, and K.pneumonia.

J. Antimicrobial Activity—ASTM: E2149-10—ZPT Used Sample

Antimicrobial testing of an inventive ZPT abrasive article sample wasconducted according to ASTM: E2149-10. In particular, the sample was aused sample (i.e., used to clean kitchen utensils). The sample was usedto wash 300 kitchen utensils by hand over an extended period of time.Dynamic action was used during the washing and each of the utensils hadfood particles that needed to be scrubbed off. The results are providedbelow.

No. of Bacteria per sample (CFU/ml) Inoculated Inoculated PercentageTreated Treated reduction Sample at Sample at of Sample Test 0 hrs. 24hrs. Bacteria Identification Organism (B) (A) (R) ZPT (1.5 wt %)- S.aureus 1.92 × 10⁵ <10 >99.99 Used Sample E. coli 2.05 × 10⁵ 4.00 × 10⁴80.48 K. pneumoniae 1.78 × 10⁵ 3.80 × 10⁴ 78.65 (R) = 100 (B − A/B)

The test results indicate that the inventive sample retained broadspectrum antimicrobial activity against S. aureus, E. coli, and K.pneumonia even after extended usage.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity can not be required, and that one or more further activitiescan be performed in addition to those described. Still further, theorder in which activities are listed are not necessarily the order inwhich they are performed.

In the foregoing specification, the concepts have been described withreference to specific embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the invention as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofinvention.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of features is notnecessarily limited only to those features but can include otherfeatures not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive-or and not to an exclusive-or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

Also, the use of “a” or “an” are employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural unless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that cancause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, can also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, can also be providedseparately or in any subcombination.

Further, references to values stated in ranges include each and everyvalue within that range. When the terms “about” or “approximately”precede a numerical value, such as when describing a numerical range, itis intended that the exact numerical value is also included. Forexample, a numerical range beginning at “about 25” is intended to alsoinclude a range that begins at exactly 25.

Embodiment 1

An abrasive article comprising:

a nonwoven substrate material impregnated with a first formulation;

wherein the first formulation has broad spectrum antimicrobialeffectiveness against one or more microbial organisms; and

wherein the first formulation comprises a first antimicrobial agent andabrasive particles uniformly dispersed in a first polymer composition.

Embodiment 2

The abrasive article of Embodiment 1, further comprising;

a coating of a second formulation disposed on a first side and on asecond side of the nonwoven substrate material,

wherein the second formulation has broad spectrum antimicrobialeffectiveness against one or more microbial organisms; and

wherein the second formulation comprises a second antimicrobial agentand abrasive particles uniformly dispersed in a second polymercomposition.

Embodiment 3

The abrasive article of Embodiment 2, wherein the broad spectrumantimicrobial effectiveness is defined as capable of killing at leastabout 75% of the population of an initial inoculation of one or moremicrobial organisms after 24 hours.

Embodiment 4

The abrasive article of Embodiment 1, wherein the one or more microbialorganisms include S. aureus, and one or more of K. pneumoniae, Bacillus,and E. coli.

Embodiment 5

The abrasive article of Embodiment 2, wherein the one or more microbialorganisms include S. aureus, and one or more of K. pneumoniae, Bacillus,and E. coli.

Embodiment 6

The abrasive article of Embodiment 5, wherein the broad spectrumantimicrobial effectiveness is defined as capable of killing at leastabout 75% of the population of an initial inoculation of E. coli after24 hours, at least 75% of the population of an initial inoculation of K.pneumonia after 24 hours, and killing at least 95% of the population ofan initial inoculation of S. aureus after 24 hours.

Embodiment 7

The abrasive article of Embodiment 2, wherein the abrasive articleretains broad spectrum antimicrobial effectiveness over at least 5000cycles of a Cycle Abrasion Test.

Embodiment 8

The abrasive article of Embodiment 1, wherein the first formulationcomprises:

0.1 wt % to 5.0 wt % of a first antimicrobial agent;

20 wt % to 70 wt % of abrasive particles; and

10 wt % to 60 wt % of a first polymer composition.

Embodiment 9

The abrasive article of Embodiment 1, wherein the first antimicrobialagent comprises triclosan, triclocarban, polyhexamethylene biguanide,zinc pyrithione, salicylic acid, benzalkonium chloride, chloroxylenol,silver, or combinations thereof.

Embodiment 10

The abrasive article of Embodiment 9, wherein the silver comprises asilver solution, a silver suspension, a silver emulsion, a silver sol, asilver gel, solid silver, a silver powder, a silver composite material,or combinations thereof.

Embodiment 11

The abrasive article of Embodiment 3, wherein the first antimicrobialagent comprises zinc pyrithione.

Embodiment 12

The abrasive article of Embodiment 3, wherein the first antimicrobialagent consists essentially of zinc pyrithione.

Embodiment 13

The abrasive article of Embodiment 3, wherein the first antimicrobialagent consists of zinc pyrithione.

Embodiment 14

The abrasive article of Embodiment 1, wherein the first polymercomposition comprises, phenolic resin, melamine formaldehyde resin, orcombinations thereof.

Embodiment 15

The abrasive article of Embodiment 14, wherein the phenolic resin is aresole resin.

Embodiment 16

The abrasive article of Embodiment 1, further comprising a filleruniformly dispersed in the first polymer composition.

Embodiment 17

The abrasive article of Embodiment 16, wherein the first formulationcomprises:

0.1 wt % to 5.0 wt % first antimicrobial agent;

20 wt % to 70 wt % abrasive particles;

10 wt % to 60 wt % first polymer composition; and

5 wt % to 30 wt % filler.

Embodiment 18

The abrasive article of Embodiment 2, wherein the second formulationcomprises:

0.1 wt % to 5.0 wt % second antimicrobial agent;

20 wt % to 70 wt % abrasive particles; and

10 wt % to 60 wt % second polymer composition.

Embodiment 19

The abrasive article of Embodiment 2, wherein the second antimicrobialagent comprises triclosan, triclocarban, polyhexamethylene biguanide,zinc pyrithione, salicylic acid, benzalkonium chloride, chloroxylenol,silver, or combinations thereof.

Embodiment 20

The abrasive article of Embodiment 19, wherein the silver comprises asilver solution, a silver suspension, a silver emulsion, a silver sol, asilver gel, solid silver, a silver powder, a silver composite material,or combinations thereof.

Embodiment 21

The abrasive article of Embodiment 19, wherein the antimicrobial agentcomprises zinc pyrithione.

Embodiment 22

The abrasive article of Embodiment 19, wherein the second antimicrobialagent consists essentially of zinc pyrithione.

Embodiment 23

The abrasive article of Embodiment 19, wherein the second antimicrobialagent consists of zinc pyrithione.

Embodiment 24

The abrasive article of Embodiment 19, wherein the second polymercomposition comprises a phenolic resin.

Embodiment 25

The abrasive article of Embodiment 24, wherein the phenolic resin is aresole resin.

Embodiment 26

The abrasive article of Embodiment 2, further comprising a filleruniformly dispersed in the second formulation.

Embodiment 27

The abrasive article of Embodiment 26, wherein the second formulationcomprises:

0.1 wt % to 5.0 wt % second antimicrobial agent;

20 wt % to 70 wt % abrasive particles;

10 wt % to 60 wt % second polymer composition; and

5 wt % to 30 wt % filler.

Embodiment 28

The abrasive article of Embodiment 1, wherein the nonwoven substratematerial comprises nylon, polyester, or a combination thereof.

Embodiment 29

The abrasive article of Embodiment 1, wherein the nonwoven substratematerial has a weight per unit area of 100 GSM to 500 GSM prior toimpregnation.

Embodiment 30

The abrasive article of Embodiment 1, wherein the nonwoven substratematerial is impregnated with 500 GSM to 800 GSM of the firstformulation.

Embodiment 31

The abrasive article of Embodiment 2, wherein the first side of thenonwoven substrate material is coated with 100 GSM to 300 GSM of thesecond formulation.

Embodiment 32

The abrasive article of Embodiment 2, wherein the second side of thenonwoven substrate material is coated with 100 GSM to 300 GSM of thesecond formulation.

Embodiment 33

A method of making an abrasive article comprising:

preparing a first formulation;

impregnating a nonwoven substrate material with the first formulation,

preparing a second formulation;

disposing the second formulation on a first side of the nonwovenmaterial substrate; and

disposing the second formulation on a second side of the nonwovenmaterial substrate to form the abrasive article,

wherein the abrasive article has broad spectrum antimicrobialeffectiveness against one or more microbial organisms.

Embodiment 34

The method of Embodiment 33, wherein the one or more microbial organismsincludes S. aureus, and one or more of K. pneumoniae, Bacillus, and E.coli.

Embodiment 35

The method of Embodiment 33, wherein preparing the first formulationcomprises:

mixing together a first antimicrobial agent, a first polymercomposition, and abrasive particles, wherein the first antimicrobialagent and abrasive particles are uniformly dispersed in the firstpolymer composition.

Embodiment 36

The method of Embodiment 33, wherein preparing the second formulationcomprises:

mixing together a second antimicrobial agent, a second polymercomposition, and abrasive particles, wherein the second antimicrobialagent and abrasive particles are uniformly dispersed in the secondpolymer composition.

Embodiment 37

The method of Embodiment 33, wherein preparing the first formulationcomprises mixing together ingredients comprising:

0.1 wt % to 5 wt % first antimicrobial agent;

10 wt % to 60 wt % phenol formaldehyde resin;

2 wt % to 20 wt % melamine formaldehyde resin;

5 wt % to 30 wt % filler;

20 wt % to 70 wt % abrasive particles; and

2 wt % to 25 wt % water.

Embodiment 38

The method of Embodiment 33, wherein preparing the second formulationcomprises mixing together ingredients comprising

0.1 wt % to 5 wt % second antimicrobial agent;

10 wt % to 25 wt % water

10 wt % to 60 wt % phenol formaldehyde resin

5 wt % to 30 wt % filler; and

20 wt % to 70 wt % abrasive particles.

Embodiment 39

The method of Embodiment 33, wherein the nonwoven substrate material isimpregnated with 200 GSM to 2000 GSM of the first formulation.

Embodiment 40

The method of Embodiment 33, wherein the first side of the nonwovensubstrate material is coated with 100 GSM to 1000 GSM of the secondformulation.

Embodiment 41

The method of Embodiment 33, wherein the second side of the nonwovensubstrate material is coated with 100 GSM to 1000 GSM of the secondformulation.

What is claimed is:
 1. An abrasive article comprising: a nonwovensubstrate material impregnated with a first formulation; wherein theabrasive article has broad spectrum antimicrobial effectiveness againstone or more microbial organisms; wherein the first formulation comprisesa first antimicrobial agent and abrasive particles uniformly dispersedin a first polymer composition; and a coating of a second formulationdisposed on a first side on a second side of the nonwoven substratematerial, and wherein the second formulation comprises a secondantimicrobial agent and abrasive particles uniformly dispersed in asecond polymer composition.
 2. The abrasive article of claim 1, whereinthe broad spectrum antimicrobial effectiveness is defined as capable ofkilling at least 75% of the population of an initial inoculation of oneor more microbial organisms after 24 hours.
 3. The abrasive article ofclaim 2, wherein the one or more microbial organisms include S. aureus,and one or more of K. pneumoniae, Bacillus, and E. coli.
 4. The abrasivearticle of claim 3, wherein the broad spectrum antimicrobialeffectiveness is defined as capable of killing at least 75% of thepopulation of an initial inoculation of E. coli after 24 hours, at least75% of the population of an initial inoculation of K. pneumonia after 24hours, and killing at least 95% of the population of an initialinoculation of S. aureus after 24 hours.
 5. The abrasive article ofclaim 1, wherein the abrasive article retains broad spectrumantimicrobial effectiveness over at least 5000 cycles of a CycleAbrasion Test.
 6. The abrasive article of claim 1, wherein the firstformulation comprises: 0.1 wt % to 5.0 wt % of a first antimicrobialagent; 20 wt % to 70 wt % of abrasive particles; and 10 wt % to 60 wt %of a first polymer composition.
 7. The abrasive article of claim 1,wherein the first antimicrobial agent comprises triclosan, triclocarban,polyhexamethylene biguanide, zinc pyrithione, salicylic acid,benzalkonium chloride, chloroxylenol, silver, or a combination thereof.8. The abrasive article of claim 7, wherein the first antimicrobialagent comprises zinc pyrithione.
 9. The abrasive article of claim 1,further comprising a filler uniformly dispersed in the first polymercomposition.
 10. The abrasive article of claim 9, wherein the firstformulation comprises: 0.1 wt % to 5.0 wt % first antimicrobial agent;20 wt % to 70 wt % abrasive particles; 10 wt % to 60 wt % first polymercomposition; and 5 wt % to 30 wt % filler.
 11. The abrasive article ofclaim 1, wherein the second formulation comprises: 0.1 wt % to 5.0 wt %second antimicrobial agent; 20 wt % to 70 wt % abrasive particles; and10 wt % to 60 wt % second polymer composition.
 12. The abrasive articleof claim 1, wherein the second antimicrobial agent comprises triclosan,triclocarban, polyhexamethylene biguanide, zinc pyrithione, salicylicacid, benzalkonium chloride, chloroxylenol, silver, or combinationsthereof.
 13. The abrasive article of claim 12, wherein the secondantimicrobial agent comprises zinc pyrithione.
 14. The abrasive articleof claim 1, further comprising a filler uniformly dispersed in thesecond formulation.
 15. The abrasive article of claim 14, wherein thesecond formulation comprises: 0.1 wt % to 5.0 wt % second antimicrobialagent; 20 wt % to 70 wt % abrasive particles; 10 wt % to 60 wt % secondpolymer composition; and 5 wt % to 30 wt % filler.
 16. A method ofmaking an abrasive article comprising: preparing a first formulation bymixing together a first antimicrobial agent, a first polymercomposition, and abrasive particles, wherein the first antimicrobialagent and abrasive particles are uniformly dispersed in the firstpolymer composition; impregnating a nonwoven substrate material with thefirst formulation; preparing a second formulation by mixing together asecond antimicrobial agent, a second polymer composition, and abrasiveparticles, wherein the second antimicrobial agent and abrasive particlesare uniformly dispersed in the second polymer composition; disposing thesecond formulation on a first side of the nonwoven material substrate;and disposing the second formulation on a second side of the nonwovenmaterial substrate to form the abrasive article, wherein the abrasivearticle has broad spectrum antimicrobial effectiveness against one ormore microbial organisms.
 17. The method of claim 16, wherein preparingthe first formulation comprises mixing together ingredients comprising:0.1 wt % to 5 wt % first antimicrobial agent; 10 wt % to 60 wt % phenolformaldehyde resin; 2 wt % to 20 wt % melamine formaldehyde resin; and20 wt % to 70 wt % abrasive particles.
 18. The method of claim 16,further comprising mixing together a filler with the first antimicrobialagent, the first polymer composition, and the abrasive particles.